Wall units with insulation

ABSTRACT

A wall unit comprising panels lying at opposite faces of said unit, a seal arranged between the margins of said panels, and an insulation occupying the cavity between said panels, wherein the improvement comprises at least one insulating group extending parallel to said panels and comprising two foils capable of reflecting thermal radiation and chambers lying between said foils, the walls of which consist of insulating material.

United States Patent [is] 3,646,721 Becker 5] Mar. 7, 1972 [54] WALLUNITS WITH INSULATION I 2,406,815 9/1946 Elfving ..52/618 X 72]Inventor: Otto Alfred Becker, 59 Robert Koch g'g g'g g gir Stmse D6600saa'bmke Gummy 3,432,859 3/1969 Jordan et a1. ....52/618 x [22] Filed:May 22, 1969 3,501,367 3/1970 Parker ..52/615 X [21] Appl' 826958Primary Examiner-Price C. Faw, Jr.

Attorney-Erich M. H. Radde 301 Foreign Applicafion Priority Data [57]ABSTRACT May 22, 1968 Germany ..P 17 59 635.9 Sept. 21, 1968 Germany 1784 816.7 A wall unit comprising panels lying at opposite faces of saidMar. 29, 1969 Germany ..P 19 16 384.9 unit. a seal us d between themargins of said p s. and an insulation occupying the cavity between saidpanels, [52] U.S.Cl ..52/6l8,52/309, 161/68 wherein the improvementcomprises at least one insulating 041) 1/74 group extending parallel tosaid panels and comprising two [58] Fieldoi Search ..52/615,6l8, 404,406, 407, foils capable of reflecting thermal radiation and chambers52/405, 269, 173, 309, 425; 161/68 lying between said foils, the wallsof which consist of insulating material. 56 References C'ted 1 -m "w' 9sfis9! UNITED STATES PATENTS 2,238,022 4/1941 Johnson ..s 2/4o4PATENTEDMAR 7 I972 SHEET 1 [IF 3 PATENTEBMAR 7 1972 SHEET 2 [IF 3 Fig.2

Fig 5 Fig.4

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il. GEES PAIENTEDMAR 7 m2 SHEET 3 [IF 3 85:1 7 51a 51b 8b WALL UNITSWITH INSULATION BACKGROUND OF THE INVENTION The present inventionrelates to a wall unit with thermal and acoustic insulation.

A known wall unit of this kind comprises two sheet metal panels of equalsize, sealing strips of resilient material arranged between the marginsof said panels, and insulating plates filling the cavity between saidpanels. When used as components of an external wall, the individual wallunits are suspended on wall supports by means of angle brackets. Similarwall units serve as partition walls extending from floor to ceiling forinternal rooms. The thermal and acoustic insulation of such wall unitsis, however, poor. The present invention has the objects of improvingthe thermal and acoustic insulation of wall units and of preventing thecorrosion thereof.

BRIEF SUMMARY OF THE INVENTION In a wall unit according to the presentinvention comprising opposite sheet metal panels, seals arranged betweenthe margins of said panels and insulation accommodated in the cavitybetween said panels, there is provided at least one insulating groupextending parallel to said panels which is composed of two high-glossfoils capable of reflecting thermal radiation, and of chambers arrangedbetween said foils, the walls of which chambers consists of insulatingmaterial. Thus a highly effective insulation is attained. Heat absorbede.g., by the outer panel is imparted to the foil on the inside thereof.From this high-gloss foil few thermal rays only are radiated, whichpenetrate through said chambers, impinge the opposite foil and arealmost completely reflected by the latter, so that this second foil isheated to a very low extent only. The walls of said chambers are made ofinsulating material, e.g., in the form of honeycombs, the webs of whichare thin, so that heat conduction through these webs is low. Thechambers are small and tightly sealed, so that likewise hardly any heattransfer takes place by convection through the air.

By arranging several such insulating groups consisting of foils andchambers one behind the others the effect is considerably increased,whereby, even the strictest requirements can be fulfilled. Between anysuch groups an insulating plate may be inserted, which reduced thethermal conduction from one foil to the other.

Between the foils also insulating plates e.g., of hardened syntheticfoam may be arranged which have on both faces ribs for the formation ofchambers. In order to reduce the contact areas, through which heattransfer takes place, an insulating plate having horizontal ribs isfollowed by an insulating plate having vertical ribs.

Instead of complete plates, strips only may be placed alternately inhorizontal and vertical positions against a reflecting foil interposedbetween them. The recesses between the ribs may be coated withreflecting adhesive tapes or the ribbed plates may be completely coatedwith a reflecting adhesive foil.

The insulating chambers may be formed by narrow insulating plates e.g.,of 5 mm. width e.g., of solidified synthetic foam perforated from faceto face and tightly sealed on both faces by highly reflective foils, theremaining structure of hardened synthetic foam constituting thegeometrical shape of the chamber walls.

Moreover the cavity between the panels may be evacuated. Any heattransfer by convection is then excluded. This entails the furtheradvantage that formation of condensate and consequent corrosion areprevented.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING Several embodiments ofthe invention are illustrated by way of example in the accompanyingdrawings, in which FIG. I is a vertical section of parts of two mutuallyabutting wall units constituting an external wall fixed to the ceilingof a building.

FIG. 2 is a vertical section of a wall unit with insulation by platesand by honeycombs.

FIG. 3 shows part of an insulating plate having horizontal ribs,

FIG. 4 of a plate having vertical ribs,

FIG. 5 of a plate having interrupted ribs.

FIG. 6 is a section a wall unit with insulation by strips and plates,and

FIG. 7 is a section of a wall unit with insulation by honeycombs and byplates covered with foils.

DETAILED DESCRIPTION OF THE INVENTION In FIG. 1 sections 1 of Z-shapedprofile are attached by means of screws In to an end face of the ceiling2 of a building. The upper section 1 carries on an outwardly directedflange an upper wall unit 3 and the lower section 1 carries the upperedge of a lower wall unit 3. Each wall unit comprises an outer sheetmetal panel 3a and an inner sheet metal panel 3b. Between the margins3c, 3d of said panels an insulating and sealing strip 10, preferably ofebonite, is inserted. Screws ll penetrate the margins, the sealingstrips 10 and the sections 1. They press the sheet metal panels in anairtight manner against each other, and at the same time support thewall units on the building. In the cavity between the sheet metal panelsan insulation is accommodated which comprises at least one highlyeffective insulating group extending parallel to said panels. Thisinsulating group comprises a thin high-gloss foil e.g., of aluminumcapable of reflecting thermal radiation, small cells 8 of about 8 mm.width, the walls of which consist of insulating material, and a secondreflecting foil, these foils sealing off said chambers.

In a first embodiment these chambers are formed by honeycomb plates 8a,the webs 8b, of which extend between the two opposite foils. Between thefoils of the three insulating groups illustrated there are moreoverinserted insulating plates 9 e.g., of feltboard or solidified syntheticfoam, for reduction of thermal conduction and for stiffening.

For improved appearance and for protection from corrosion each of thesheet metal panels is provided outside with a coating 4 of lacquer orsynthetic material, and inside with a foil 5 of a sounddeadeningmaterial and a stiffening sheet metal panel 6.

Upon solar radiation of the outer sheet metal panel also the adjoiningfirst foil is warmed. However, the high-gloss foil radiates but littleheat inwards, namely about one-fifth of the radiation emitted by a blackbody. The heat radiation emanating from the foil penetrates thechambers, impinges the opposite foil and is almost completely (say 93percent) reflected by the high-gloss surface of the latter and isabsorbed only to a small proportion (7 percent), so that the oppositefoil is warmed up but little and can discharge little heat (1.25percent) only. Heat transfer by radiation is accordingly very small.Moreover heat conduction takes place through the edges of the webs ofthe honeycomb contacting the foils. However, since the cross sectionalarea of the webs contacting the foils amounts to about 4 percent only ofthe whole area of a foil, and the webs consist of insulating material,also the heat conduction is very low. Finally heat could be transferredby convection through the enclosed air. However, since a great many andconsequently small cells are formed by the honeycomb plates, an airflowand consequent heat transfer can hardly take place. When severalinsulating groups are arranged in series, their effect is greatlyincreased. In a test with five insulating groups, the outer sheet metalpanel was raised to a temperature of C. and kept at that temperature,while the inner sheet metal panel was exposed to a room temperature of20 C. After four hours a steady condition was attained in which thetemperature of the inner sheet metal panel had increased from 20 C. to30 C. At an external temperature of 70 C. the temperature of the innersheet metal panel rose by 7 C. and at an external temperature of 45 C.by 3 C. only.

The walls of the honeycomb cells may be provided with highly reflectivevery thin metal surface layers (e.g., by deposition of aluminum from thevapor phase in vacuo). For reasons of fire protection the honeycombs maybe made fireproof by impregnation of the like. Likewise mats of glassfibers may be arranged as an insulation on the internal surfaces of thewall panels as well as e.g., between two aluminum foils whereby the wallunits, in conjunction with the reflecting metal foils and sheet metalpanels (thermal reflection) and the impregnated and hardened honeycombs,are made extraordinarily fireproof.

The gaps between any two adjacent wall units may be outwardly closed byangle sections 13 held by screws 11 and by screens 14, which engagebehind resilient tongues in said angle sections. For further thermal andacoustic insulation from the interior space the inner sheet metal panelsmay each carry a reflecting foil and spacer strips 15. On the latter aplate 16 of plaster of Paris and covered on both surfaces withreflecting foils is placed, which is attached to the buildings by anglesections 17 and forms the inner wall surface thereof.

A second embodiment is illustrated in FIGS. 2-5. The wall units 3comprises an outer sheet metal panel 3a and an inner sheet metal panel3b. Each of them has a coating 4. The inserted insulation comprises sixinsulating groups. The two middle groups are made of honeycomb plates 80as in the first embodiment. The outer groups are formed by insulatingplates 51, e.g., of hardened synthetic foam, which have narrow ribs 51aabout mm. wide on both faces and form strip-shaped chambers 8. In FIG. 3an insulating plate is illustrated in elevation having horizontal ribs 5la, in FIG. 4 a plate with vertical ribs 51b and in FIG. 5 one with rowsof projections 51c.

The first insulating plate is followed by a second reflecting foil andby a second insulating plate, the ribs of which run at right angles tothose of the first insulating plate; thus thermal conduction can occurat the crossing points only of the ribs. A third reflecting foil sealsthese chambers off. Between the insulating groups sheet metal panels 9may be arranged which prevent any buckling of the thin reflecting foilunder major pressures e.g., upon evacuation, which may be caused by thewebs of the honeycomb plates or ribs of the insulating plates beingjuxtapositioned to each other on points only.

When the sheet metal panels themselves are highly reflective, the foilsmay be dispensed with.

In a third embodiment, instead of insulating plates, insulating stripsonly are used, the contact surfaces of which have ribs. In FIG. 6 thesheet metal panels 3a, 3b are provided externally with coatings 4. Thefirst insulating group is formed by horizontal insulating strips 52 withribs 52a, which may be attached by glueing to the contacting reflectorfoils 7. The second group has vertical insulating strips 53 with ribs53a. Then follows a third group with horizontal strips and a fourthgroup with vertical strips. In the chambers between these insulatingstrips heat transfer by convection hardly occurs. In the middle of theunit two groups are arranged each with insulating plates 51 havinghorizontal ribs and corresponding reflector foils. Moreover reflectorfoil strips 7a are inserted into the recesses, whereby thermal radiationinto the insulating plate is strongly reduced.

In a fourth embodiment according to FIG. 7 two insulating groupscomprising honeycomb plates 8a and associated reflector foils 7 contacteach of the sheet metal panels 30, 3b from inside, which panels havingcoatings 4 outside. In the middle an insulating group is arrangedcomprising an insulator plate 51 having ribs 51a on both faces. Theseribs may be produced by pressing or rolling. At the same time reflectorfoils may be attached by glueing, so that the surfaces of the insulatingplate are completely covered by reflector foils.

Instead of being made of sheet metal, the external panels of the wallunit may be made of the other materials, e.g., of synthetic substances.

Further improvement of the insulation may be attained by evacuating theair from the cavity between the sheet metal panels. For this purpose theindividual wall elements may be provided with valves, or all the wallelements may be connected to a vacuum pump by a pipe line. Evacuationprevents any heat transfer by convection. Moreover, the formation ofcondensate is prevented which condensate might reduce the reflectivityof the high-gloss reflector foils.

The thermal insulation properties of the wall units described hereinabove apply substantially likewise to acoustic insulation.

When the air is not evacuated, it has to be displaced by dried air. Theairtight wall units are to be connected by pipe lines to an air-dryingplant. Corresponding to the atmospheric fluctuations of air pressure,dried air is additionally received by the wall units from this airdrying plant when the atmospheric pressure rises, and discharged by thewall unit into said plant when the atmospheric pressure drops. Thepressure in the wall unit thus is at any time in equilibrium with theatmospheric pressure, without humidity being able' to enter into thewall unit.

I claim:

1. A wall unit comprising panels lying at opposite faces of said unit, aseal arranged between the margins of said panels, an insulationoccupying the cavity between said panels, said insulation comprising aninsulating group extending parallel to said panels and comprising atleast two foils capable of reflecting thermal radiation, and chamberslying between said foils, the walls of said chambers consisting ofinsulating plates of hardened synthetic foam material being arrangedbetween said foils, said plates having ribs on both surfaces for theformation of strip-shaped chambers between them, the ribs of saidinsulating plates crossing those of the insulating plates of adjacentinsulating groups.

2. A wall element according to claim 1, wherein an insulator plate (9)is arranged between said two insulator groups when each said groupcomprises two reflector foils and a free chamber therebetween.

3. A wall element according to claim 1, wherein there is a middlereflector foil (7) supported by ribs (51a, 51b), and subdividing meanson the chambers for dividing the radiation into each of the tworadiation chambers.

4. A wall unit comprising panels lying at opposite faces of said unit, aseal arranged between the margins of said panels, an insulationoccupying the cavity between said panels, said insulation comprising aninsulating group extending parallel to said panels and comprising atleast two foils capable of reflecting thennal radiation, and chamberslying between said foils, the walls of said chambers consisting ofinsulating plates of hardened synthetic foam material being arrangedbetween said foils, said plates having ribs on both surfaces for theformation of strip-shaped chambers between them, and strips ofreflecting foils coating said insulating plates between said ribs.

5. A wall unit comprising panels lying at opposite faces of said unit, aseal arranged between the margins of said panels, an insulationoccupying the cavity between said panels, said insulation comprising aninsulating group extending parallel to said panels and comprising atleast two foils capable of reflecting thermal radiation, and chamberslying between said foils, the walls of said chambers consisting ofinsulating plates of hardened synthetic foam material being arrangedbetween said foils, said plates having ribs on both surfaces for theformation of strip-shaped chambers between them, and reflecting foilscoating said insulating plates over their entire surfaces.

nun-u

1. A wall unit comprising panels lying at opposite faces of said unit, aseal arranged between the margins of said panels, an insulationoccupying the cavity between said panels, said insulation comprising aninsulating group extending parallel to said panels and comprising atleast two foils capable of reflecting thermal radiation, and chamberslying between said foils, the walls of said chambers consisting ofinsulating plates of hardened synthetic foam material being arrangedbetween said foils, said plates having ribs on both surfaces for theformation of strip-shaped chambers between them, the ribs of saidinsulating plates crossing those of the insulating plates of adjacentinsulating groups.
 2. A wall element according to claim 1, wherein aninsulator plate (9) is arranged between said two insulator groups wheneach said group comprises two reflector foils and a free chambertherebetween.
 3. A wall element according to claim 1, wherein there is amiddle reflector foil (7) supported by ribs (51a, 51b), and subdividingmeans on the chambers for dividing the radiation into each of the tworadiation chambers.
 4. A wall unit comprising panels lying at oppositefaces of said unit, a seal arranged between the margins of said panels,an insulation occupying the cavity between said panels, said insulationcomprising an insulating group extending parallel to said panels andcomprising at least two foils capable of reflecting thermal radiation,and chambers lying between said foils, tHe walls of said chambersconsisting of insulating plates of hardened synthetic foam materialbeing arranged between said foils, said plates having ribs on bothsurfaces for the formation of strip-shaped chambers between them, andstrips of reflecting foils coating said insulating plates between saidribs.
 5. A wall unit comprising panels lying at opposite faces of saidunit, a seal arranged between the margins of said panels, an insulationoccupying the cavity between said panels, said insulation comprising aninsulating group extending parallel to said panels and comprising atleast two foils capable of reflecting thermal radiation, and chamberslying between said foils, the walls of said chambers consisting ofinsulating plates of hardened synthetic foam material being arrangedbetween said foils, said plates having ribs on both surfaces for theformation of strip-shaped chambers between them, and reflecting foilscoating said insulating plates over their entire surfaces.